1. All you want to know about plunger lift!

2. Training Overview Introductions Goals and Objectives
How do plungers work?
Why do we need plungers?
Automation Capabilities
How to detect a problem?
What to do if there is a problem…
Review
QUIZ TIME!
Field Training

3. Introductions Name Job Title One thing you love about plunger lift…
One thing you hate about plunger lift…

4. Goals and Objectives Overall Goal
To familiarize and train operators how to optimize production using plunger lift
Objectives
To encourage proper operation of PL equipment and software
To minimize plunger equipment downtime
To encourage operators to increase interaction with current method of artificial lift (plunger lift)

5. What does a plunger do?

6. Plunger Lift Overview
Plunger Lift is a method of reducing liquid fallback in two phase production (liquid & gas)
Plunger serves as a mechanical interface between these two phases (liquid & gas)
Plunger increases efficiency of lifting liquids in gas/liquid production

7. Plunger Lift Overview
While well is flowing, fluid accumulates in bottom of tubing string
Well must be shut in to allow plunger to fall to bottom and to build pressure
Liquid accumulates in tubing above plunger
Gas pressure builds in casing & tubing
After pressure builds to a sufficient value, flowline is opened

8. Controller/ Measurement
Plunger Lift Overview
Tubing Valve
Controller/ Measurement
Casing Valve
Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate
Add plunger lift to increase efficiency of system
Can switch control to tubing/casing flow

9. Plunger Lift Overview
While well is flowing, fluid accumulates in bottom of tubing string
Well must be shut in to allow plunger to fall to bottom and to build pressure
Liquid accumulates in tubing above plunger
Gas pressure builds in casing & tubing
After pressure builds to a sufficient value, flowline is opened

10. Controller/ Measurement
Plunger Lift Overview
Tubing Valve
Controller/ Measurement
Casing Valve
Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate
Add plunger lift to increase efficiency of system
Can switch control to tubing/casing flow

11. Plunger Lift Overview
While well is flowing, fluid accumulates in bottom of tubing string
Well must be shut in to allow plunger to fall to bottom and to build pressure
Liquid accumulates in tubing above plunger
Gas pressure builds in casing & tubing
After pressure builds to a sufficient value, flowline is opened

12. Plunger Lift Overview
When well is opened, gas stored in casing as well as gas from formation create pressure differential across plunger
Stored casing gas moves around end of tubing
Plunger begins to rise with accumulated fluid above plunger
Plunger arrives at surface with fluid slug

13. Controller/ Measurement
Plunger Lift Overview
Tubing Valve
Tank Valve
Controller/ Measurement
Casing Valve
Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate
Add plunger lift to increase efficiency of system
Can switch control to tubing/casing flow

14. Plunger Lift Overview
When well is opened, gas stored in casing as well as gas from formation create pressure differential across plunger
Stored casing gas moves around end of tubing
Plunger begins to rise with accumulated fluid above plunger
Plunger arrives at surface with fluid slug

15. Controller/ Measurement
Plunger Lift Overview
Tubing Valve
Tank Valve
Controller/ Measurement
Casing Valve
Improve GLR to unload liquids, measure tubing flow and inject gas to keep at unloading rate
Add plunger lift to increase efficiency of system
Can switch control to tubing/casing flow

16. Plunger Lift Overview
After plunger arrival, gas is produced for some period of time, depending on well
Some wells afterflow for long periods
Some wells afterflow for short periods
Depends on GLR of well
Well shuts in and cycle starts over again

17. Plunger Lift Cycles
Pressure Buildup
Shut-in
Unloading
Flowing-Loading

18. The plunger adds a mechanical seal
Gas Flow

19. FB Demonstration Surface Equipment Downhole Equipment
Receiver/Lubricator
Preventative Maintenance
Repair
Plunger
Plunger types
Maintenance
Downhole Equipment
Collar Stop/Bumper Spring
How does a CS/BS work?
Automation Equipment
Intermitter Valve
Electronic Controller (ROC)

20. PLUNGER-LIFT
OVERVIEW
A typical system is
comprised of a:
Plunger
Collar Stop
Lubricator /
Catcher
Controller/
Motor Valve

21. Lubricator/Catcher Products
Lubricator – Spring absorbs impact of
plunger arriving at surface
Catcher – Allows you to catch plunger in lubricator mechanically to either inspect or to change

22. Lubricator/Catcher Products

23. Plungers
Our BeauFlex plunger is designed to provide maximum sealing integrity with minimum gas slippage. It’s sealing capability allows it to be used in wells where there is not enough gas to operate other types of plungers.

24. Plungers
Ferguson Beauregard’s Mini-Flex plunger features 8 interlocking stainless steel pads to create a superior seal. The spring-loaded pads are always expanded yet have enough flex to allow the plunger to fall through minor tubing anomalies.

25. Plungers
The Duo-Flex is designed for gas wells and high ratio oil wells where sealing efficiently is critical. With 16 interlocking stainless steel pads, it travels with less pressure and with less gas slippage.

26. Downhole Products
Ferguson Beauregard down hole springs and stops are engineered and manufactured in a variety of configurations.

27. Why do I need a plunger?

28. Liquid Loading
All gas wells, at some time during there producing life, will experience liquid loading problems
Liquid Loading occurs when a well’s gas velocity is no longer able to carry the well’s fluids to the surface
These fluids fall back and are suspended in the wellbore and/or accumulate in the bottom of the well
This additional head increases the flowing bottomhole pressure(FBHP), reduces reservoir drawdown, and thus gas production

29. Liquid Loading
The gas rate at which liquid loading occurs is called the Critical Rate, and is primarily a function of tubing ID and Flowing Tubing Pressure (FTP).
Gas flow is in heads (slug flow) or bubble flow (gas bubbles through liquids)
Loads up during flow

31. Liquid Loading Detection
Decrease in Production
Wells being swabbed, blown down, etc.
Sales Charts
Production Decline Curves
Pressure difference between casing & tubing

32. Conclusions
Plunger-Lift remains the most economical form of artificial lift
Plunger-Lift also remains more time consuming and requires
more monitoring than other forms of artificial lift. This can be
reduced by the addition of plunger lift telemetry.
There are several types of control methods other than
conventional plunger lift that might be better suited for your
situation.
Not a cure all – Certain parameters must be met for a successful
installation.

33. BREAK TIME! Take a 10 minute break!

34. Automation Capabilities
Viewclient
Up to the minute production info
Plunger Settings
Minute Histories

35. East Texas/North Louisiana Viewclient

36. Screenshot: Oletha/Pearwood

37. Production Screen with Plunger Settings Box

38. Minute Histories

39. Plunger Settings Tubing Setpoint (psig) Low Flow Setpoint (MCF)
Low Flow Time Delay (min)
Max Flow Setpoint (MCF)
PID Valve Output (%)

40. Plunger Settings Tubing Setpoint
Pressure setting that triggers valve to open after pressure build-up
Should be at least the minimum pressure needed to unload the well (Turner Chart)
Varies for each well

41. Plunger Settings Low Flow Setpoint Low Flow Time Delay
Minimum rate well can flow without loading
Should be at least the minimum rate needed to unload the well (Turner Chart)
Low Flow Time Delay
Amount of time well will flow after reaching Low Flow Setpoint
Setting is useful since wells may spike up and down while unloading
Each time the low flow rate is reached a timer begins and will shut once that rate or lower has lasted for the time setpoint
Typically 10 or 15 minutes is used

42. Plunger Settings Max Flow Setpoint PID Valve Output
Maximum flow rate the intermitter valve will allow when opening
Prevents extremely high rates that over-range the meter
PID Valve Output
Displays percentage of the valve open
If valve shows 0%, the well should not be flowing

43. Examples Leaking valves Valves not opening Valves not closing
Opened bypasses
Properly working valves

64. How to Detect a Problem…
Troubleshooting
How to Detect a Problem…

65. Common Problems
Constant pressure build-up but valve is opening/closing
Casing pressure is extremely high while tubing pressure is low or zero
Well producing while PID valve output is 0% or closed
Opened bypasses
Well flowing too long and loads up

66. Field Operator Responsibilities Automation Tech Responsibilities
Possible Causes
Field Operator Responsibilities
Plugged Orifice
Supply Gas Problem
plugged screens
bad regulator
Cut Out Seat/Trim
Bypass Cracked Open
Automation Tech Responsibilities
Requires Recalibration
Wiring Problem
I/P Motor Valve Problem

67. Things to Remember… Don’t open the bypass unless someone is informed
Never adjust I/P zero setpoint or spring tensions on valve
Supply regulator needs to be psig

68. COGZ Work Order Request
Go to Start Menu
→All Programs
→Citrix ICA Client
→MGROUP Program Neighborhood
Insert User Name and Password
Go to Houston Apps
→COGZ Work Order Request
Click “Add Request”
→Insert requested information
→Click OK

69. BREAK TIME! Take a 5 minute break!

70. Review How plungers work Why we need plungers Automation Capabilities
Settings & Minute Histories
How to detect a problem
What to do if there is a problem

71. QUIZ TIME!

72. Name 2 of the 4 plunger settings that can be adjusted or changed
Question 1
Name 2 of the 4 plunger settings that can be adjusted or changed

73. Question 2
What’s wrong?

74. Question 3
What’s wrong?

75. Question 4
If the field operator cannot fix a valve problem, what’s the next step?

76. Question 5
Plunger lift is great!
True or False

77. Conclusion Plunger lift is a permanent part of our field
Operators are required to interact with plunger equipment, settings, etc
Everyone is here to help!!

78. Field Training How to check for a damaged valve How to replace a valve
How to check for supply gas problems
Then…
LUNCH!

79. Questions?